Apparatus and methods for making pile articles and improved pile articles made therewith

ABSTRACT

Filamentary materials, such as yarn ( 18 ), is wound a frame ( 28 ), provided by pairs of movable filaments or wires ( 35, 38 ), about which the end of the spindle ( 22 ) rotates provides the turns ( 26 ) of the winding as the article having the winding is moved along a process path. Mechanically or hydraulically actuated pins ( 34 ) support the winding frame in a fixed position. The filaments of the frame may be provided by laterally spaced pairs ( 44, 46 ) of filaments of weldable material.

The present invention relates to apparatus and methods for making pilearticles of filamentary materials, such as yarn and thread, whicharticles are especially suitable for use as weatherseals or bristles forbrushes. A weatherseal made using the apparatus and methods of theinvention may have a continuous loop supported at the ends thereof so asto form a bow or arch which provides resilient support for a frame,door, or window sash.

This invention is an improvement over the methods and apparatus forfabricating pile articles, especially brushes and weatherseals bywinding the filamentary material (referred to herein as yarn) about aframe around which a spindle rotates. The frame is provided by pairs offilaments which define the ends of the loops of yarn wound on the frameas the spindle rotates thereabout. Such methods and apparatus are thesubject matter of International Patent Application No. PCT/US04/43314,filed Dec. 17, 2004. The pile articles provided by the present inventionhave continuous pile loops which need not be slit in order to remove thearticle from the apparatus from which it is made. Such continuous looppile articles may have the pile configured so as to provide a resilientsupport. The support may be provided by a bow or arch of the loops. Thepile articles provided by the invention are improvements over pilearticles described in International Patent Application No.PCT/US03/34393, filed Oct. 30, 2003, published under InternationalPublication No. WO 2004/042248 on May 21, 2004, and International PatentApplication No. PCT/US04/12878, filed Apr. 27, 2004.

Pile articles, such as weatherseals and brushes, especially used fordischarge of static electricity and methods and apparatus for makingthem by winding of yarn around a moving band or mandrel, are describedin Horton, U.S. Pat. No. 4,148,953 issued Apr. 10, 1979, and Horton,U.S. Pat. No. 4,302,494 issued Nov. 24, 1981, and also in Johnson etal., U.S. Pat. No. 5,338,383 issued Aug. 16, 1994. Methods and apparatususing winding techniques to make brushes for discharge of staticelectricity are described in Loughney et al., U.S. Pat. No. 6,252,757issued Jun. 26, 2001.

U.S. Pat. No. 6,711,858 issued Mar. 20, 2004 to James V. Albanese andDavid N. Hawkins also describes pile articles, particularlyweatherseals, which may be made by the methods and apparatus provided bythe invention.

In the method and apparatus of that International Application No.PCT/US04/43314, the frame is fixedly supported at the upstream end ofthe process path, along which the pile articles are produced, byutilizing a scotch yoke mechanism. The scotch yoke is contained in asupport at the upstream end of the path from which the frame formingfilaments extend to define the winding frame. The scotch yoke drivespins to execute reciprocal motion across a gap through which the windingspindle rotates. The gap is between a frame support including the scotchyoke and an external yoke which forms a stationary base. The pins arereciprocated in synchronism with the rotation of the spindle.Accordingly, even though one or more of the pins enters the externalyoke to provide a stationary support for the frame, the pins retract andclear the gap to provide clearance for the spindle. The scotch yoke issubject to vibration as it operates; thus limiting the speed ofreciprocation of the support pins and the winding rate, which isdetermined by the speed of rotation of the spindle. One importantfeature of the present invention to enable the pile articles made bywinding of the yarn around the frame at a faster rate than maypractically be obtained with the methods and apparatus described inInternational Patent Application No. PCT/US04/43314.

The production rate is also enhanced, in accordance with the feature ofthe invention, by binding the ends of the loops through the use ofultrasonic energy. The application of such energy facilitates the use ofultrasonic weldable material such as plastic monofilaments (preferablyof the same material as the yarn) to provide the winding frame. Suchfilaments, and if desired a backing strip, may be welded together withthe yarn loops at the ends of the loops, preferably with the aide ofultrasonic welding heads.

A further feature of the invention is to provide weatherseals havingcontinuous loops which need not be slit in order to remove the assembledweatherseals from the winding frame. To this end, the winding frame maybe provided by loops of wire which extend to the upstream end thereof atthe support. The support is maintained stationary, preferably bymechanical, fluid pressure operated (pneumatic or hydraulic) orelectromagnetic means provided by the invention. The loops of thewinding frame terminate at the upstream end of the process path andextend along the path downstream from the station where attachingmembers, such as the backing strips mentioned above, may be assembled,preferably by ultrasonic welding, to the ends of the loops. The yarnloops themselves pass around the frame forming loops and thus need notbe cut in order to remove the pile article from the winding frame.

The invention provides, therefore, a weatherseal made of a continuousloop attached only at the ends thereof and which may be arranged in abow or arch or in a bridge for supporting and/or sealing a window sashor doorframe.

Still another feature of the invention is providing methods andapparatus for producing pile articles at high speed, even though thewinding frame is held rotationally stationary and the winding spindlemust rotate about the winding frame. This feature may be accomplishedusing a stationary base. Mechanically or fluid pressure actuated pinsare movable by the base across the gap to the frame support. Theactuating mechanism may be coupled to a shaft which rotates the spindleso as to synchronize the movement of the pins with the rotation of thespindle, thereby insuring that the pins clear the gap when the spindlespass the pins. At least one of the pins is in supporting relationshipwith the frame so that the frame is held in a stationary fixedrelationship with the base. An electromagnetic structure for supportingthe frame and allowing the spindle to pass unobstructed through the gapmay be afforded by a stator ring connected to the base, which ismagnetically coupled to an armature attached to the support for theupstream end of the frame. The magnetic field may be provided bypermanent magnets in the stator which direct the field to the armatureand hold the armature stationary, and the winding frame support with thestator.

The foregoing and other objects, features and advantages of theinvention will become more apparent from a reading of the followingdescription in connection with the accompanying drawings which aredescribed briefly as follows:

FIG. 1 is a perspective view schematically illustrating the apparatus inaccordance with a first embodiment of the invention, wherein amonofilament of ultrasonically weldable material provides the windingframe in a winding station where the loops of yarn are wound to form thepile;

FIG. 2 is a plan view of the winding and binding station of theapparatus as shown in FIG. 1;

FIG. 3 is a fragmentary sectional view taken along the line 3-3 in FIG.2;

FIG. 4 is a perspective view schematically illustrating the apparatus inaccordance with another embodiment of the invention utilizing a pair ofwire loops to provide the winding frame in the winding station and tosupport the wound loops in the binding section of the apparatus;

FIG. 5 is a plan view of a still further embodiment of the apparatusembodying the invention wherein the loops which define the windingstation extend to a position between the binding station and the drivingstation and are sufficiently limited in height to enable pile made ofcomplete loops where the loops are not slit, as in the apparatus shownin FIGS. 1 and 4;

FIG. 6 is a plan view of the winding and binding stations in FIG. 5,illustrating the path of the wire loops which define the frame on whichthe yarn is wound;

FIGS. 6A and 6B are perspective views of different mechanisms wherebythe wire loops may be supported;

FIG. 7 is an end view along the line 7-7 in FIG. 6 illustrating thesupport of the downstream end of the frame forming loops;

FIG. 8 is a perspective view taken from the top of the apparatus formaking pile articles having mechanically operated means for maintainingthe winding station stationary while the spindle wraps the yarn aroundthe frame in the winding station;

FIG. 9 is a sectional view of the mechanism shown in FIG. 8 taken alongthe line 9-9 and viewed in the direction of the arrows;

FIG. 10 is a perspective view showing mechanism for maintaining thewinding station stationary which is fluid pressure operated;

FIG. 11 is a fragmentary sectional of the mechanism taken along the line11-11 in FIG. 10, when viewed in the direction of the arrows;

FIG. 12 is a schematic diagram of the fluid pressure circuits of themechanism illustrated in FIGS. 10 and 11;

FIG. 13 is a perspective view illustrating a magnetically operatingmechanism for maintaining the winding station stationary;

FIG. 14 is a sectional view of the mechanism shown in FIG. 13 takenalong the line 14-14 in FIG. 13 when viewed in the direction of thearrows;

FIG. 15 is a sectional view through the continuous loop pile articlewhich is made with the apparatus illustrated in FIGS. 5-7;

FIG. 16 illustrates the pile article shown in FIG. 15 configured to forma bow or arch so as to provide a weatherseal;

FIGS. 16A and 16B show the pile article of FIG. 16 configured to providea weatherseal for a door or for double doors, respectively;

FIG. 17 is a sectional view illustrating the installation of the pilearticle shown in FIG. 15 where the backings are joined together;

FIGS. 17A and 17B are views similar to FIGS. 16A and 16B showinginstallations of the pile article as a weatherseal;

FIG. 18 illustrates a pile article shown in FIG. 15 configured forinstallation in T-slots of a frame;

FIGS. 18A and 18B are views similar to FIGS. 16A and 16B showingapplications of the article illustrated in FIG. 18 as weatherseals fordoors or panels;

FIG. 19 is a sectional view illustrating the installation of acontinuous loop pile article such as shown in FIG. 16, 17 or 18providing a door sweep;

FIG. 20 is a sectional view illustrating another installation of a pairof pile articles such as shown in FIG. 16, 17 or 18 to provideweatherseals for door panels which can swing inwardly and outwardly intoclosing and opening relationships;

FIG. 21 is a sectional view schematically illustrating a pile article asshown in FIG. 16, 17 or 18 used as a sliding weatherseal;

FIG. 22 is a sectional view schematically illustrating the installationof a pile article as shown in FIG. 16, 17 or 18 as a compression seal ona sash which closes against a sill;

FIG. 23 is a sectional view schematically illustrating a pile articlesuch as shown in FIG. 16, 17 or 18 providing a sliding door seal;

FIG. 24 is a sectional view schematically illustrating a continuous looparticle such as shown in FIG. 16, 17 or 18 providing a seal in a frameagainst a swinging door or sash;

FIG. 25 is a sectional view schematically illustrating the installationof a pile article where the pile is made of conductive yarn as aelectrostatic discharge device;

FIG. 26 is a sectional view schematically illustrating the use of pilearticles similar to those shown in FIG. 16, 17 or 18 and particularlythe pile articles in FIG. 18 as seal for a moving medium, such as paper,the installation providing an electrostatic discharge device forelectric charges collected on the medium;

FIG. 27 is a sectional view schematically illustrating a pile articleshown in FIG. 18 used as a hinge for a screen door or panel;

FIG. 28 is a sectional view schematically illustrating the installationof a pile article, such as shown in FIG. 15, in a frame to provide aguide strip and seal for the end of a panel which moves along the loopof pile in a directional perpendicular to the plane of the drawing;

FIG. 29 is a sectional view schematically illustrating the use of acontinuous pile article for providing a seal between panels;

FIG. 30 is a perspective view of the pile article seals shown in FIG. 29having a slot therethrough through which items may pass, the seal actingas a light dust or dirt seal around the item in or passing through theslot or if the pile is conductive as to facilitate discharge of staticcollected on the items;

FIG. 31 is an elevational view of a circular ring formed by a pilearticle, such as shown in FIG. 15, which provides a spring havingresiliency for supporting loads applied in a direction along the loopsof yarn in the pile;

FIG. 32 is an end view showing the spring illustrated in FIG. 31 inoperation;

FIG. 33 is a perspective view schematically showing a pile articlesimilar to the article illustrated in FIG. 15 configured in a looparound pulleys so as to provide a flexible belt which may serve as aconveyor;

FIG. 34 is a sectional view taken along line 34-34 in FIG. 33 whenviewed in the direction of the arrows;

FIGS. 35A and 35B are plan and sectional views, respectively,illustrating a pile article similar to the article shown in FIG. 15which can be sewn into an opening for providing a light block inupholstery, carpet, seat cover or clothing;

FIG. 36 is a perspective view schematically illustrating theincorporation of fin material into the pile article between the sides ofthe loops of yarn thereof; and

FIGS. 37A and 37B are sectional views illustrating the pile article ofFIG. 15 where the backings are perpendicular to each other as in theinside corner of a frame (FIG. 37B) so that the bow or arch extendsacross the corner and provides a resilient support and may provide aseal against a member which moves with respect to the frame into thecorner.

DETAILED DESCRIPTION

Referring to FIGS. 1, 2 and 3, there is shown an apparatus for makingpile articles, more particularly a pair of pile weatherseals orweatherstripping 10 and 12, similar to the weatherstripping shown in theabove referenced Horton and Johnson et al. patents. The process path formaking the weatherstripping starts with an array of a plurality ofstationary spools, two of such spools 14 and 16 are shown in FIG. 1 tosimplify the illustration. Filamentary material provides the pile of thepile article product 10 and 12. The filamentary material is yarn ofultrasonically weldable material, such as polypropylene. The yarn isformed by twisting threads 18 as they are drawn from the spools 14 and16 in a tubular shaft 20. A hollow spindle 22 is attached at a collar 24and rotated with the shaft 20. A gear or belt drive which rotates theshaft 20 is not shown in FIG. 1. Yarn is drawn from the spindle andhelically wound into loops 26 at a stationary winding station 28. Theterm yarn is used generically herein to note the filamentary materialwhich is wound to form the pile of the pile article product, which inthe illustrated case are the pile weatherseals 10 and 12.

The winding station 28 is supported in fixed or stationary position by amechanism in a support structure 30. The shaft 20 may be journalled inbearings in the support structure 30. The support structure 30 is heldstationary, in a manner to allow the rotation of the spindle 22 aboutthe support structure, by means of a stationary yoke 32. Pins 34 arereciprocated outwardly from the ends of the support structure intoopenings 36 in the yoke 32. The reciprocation is motivated by a scotchyoke mechanism in the support structure 30 which is driven by the shaft20. Preferably the support structure 30 and winding station 28 aremaintained fixed and stationary by pins which are driven inwardly bymechanical or fluid (pneumatic) drive means from the yoke 32, asdiscussed hereinafter in connection with FIGS. 8 and 9 for themechanical drive means, and in connection with FIGS. 10-12 for the fluidactuated (pneumatic) drive means. The mechanical and pneumatic drivemeans are actuated in synchronism with the rotation of the shaft 20 sothat the pins clear the gap through with the spindle 22 rotates as thespindle passes the support structure. The support structure 30 and thewinding station 28 may also be held stationary magnetically by meanswhich establishes a stationary magnetic field which extends through thepath of rotation of the spindle 22. The spindle 22 then being made ofnon-conductive material. The magnetic support constitutes a magneticchuck and is described hereinafter in connection with FIGS. 13 and 14.

As shown in FIGS. 1-3, the winding frame, on which the loops of yarn arewound, is provided by pairs of filaments 35 and 38, preferably plasticmonofilaments; the material being ultrasonically weldable. Polypropylenemonofilaments are especially suitable for use in providing the windingframe. Specifically, the monofilaments 35 and 38 are drawn from spools(not shown). A first set of rollers 40 guides the monofilament 35 and asecond similar set of rollers 42 guides the monofilament 38. Thus, thewinding frame is provided by parallel loops 44 and 46 of themonofilaments 35 and 38, respectively. These loops 44 and 46 have innersides 48 and 50 which extend from the roller sets 40 and 42,respectively. The monofilaments enter through the loops of yarn, afterthey are slit, by a slitter, such as a knife blade 52. The loops 44 and46 have outer sides 54 and 56, respectively, which define the ends ofthe loops 26 of yarn.

Rollers 58 and 60 which are free to turn, and turn in the direction ofthe arrows 61 and 63 on shafts attached to a bracket 62. Themonofilament loops 44 and 46, on the outsides 54 and 56 thereof, areguided by pins 64 and 66 projecting from the bracket 62. The filamentson the outsides 54 and 56 of the loops are drawn in the direction of thearrows 68 and 70 along the process path.

The loops of yarn are assembled, by ultrasonic welding, at a bindingstation 72 spaced along the process path from the winding station 28 bya distance sufficient to enable a few loops to be wound around thewinding frame provided by the monofilament loops 44 and 46. The densityof the pile depends on the density of the yarn as it is wound. Thisdensity is controlled by the speed of travel of the pile product alongthe process path.

The binding station 72. is provided by a pair of ultrasonic horns 74 and76 which are driven by ultrasonic vibrators (not shown) to vibrate in alateral direction (transverse to the processing path) against an anvil78. The anvil 78 is attached at one end thereof to the bracket 62 andmay be thinner (starting at a step, 80) than a tongue 82 of the anvil78. The anvil 78 may have notches 84 and 86 (FIG. 3), along the edgesthereof, in which the outsides 54 and 56 of the monofilament loops 44and 46 are guided. The insides 48 and 50 of the loops 44 and 46 may beguided by other notches 88 and 90 in the surface of the anvil.

Backing strips 92 and 94 of ultrasonically weldable material, such aspolypropylene, are guided from spools thereof (not shown) into notches96 and 98 (FIG. 3) in the welding heads (also called horns) which aredisposed in contact with the opposite ends of the loops 26. Thesebacking strips may have channels in which the opposite ends 100 and 102of the yarn loops are aligned. The backing strips may be similar to thebacking strips used in providing the weatherseals in the abovereferenced Horton and Johnson et al. patents.

At the binding station 72, the monofilaments 35 and 38 (at theiroutsides 54 and 56 of the frame loops), the yarn loops 26, and thebacking strips 92 and 94 are ultrasonically welded together into acomposite, assembled pile article. If desired, the pile article may bemade without backing strips, in which the assembly consists of the yarnand the monofilaments which are bound (welded) at the ends of the loops.The loops may be backed by textile or fabric bands instead of plasticbacking strips. These bands facilitate installation of pile articles bysewing into a support (see FIG. 35). Textile backed pile articles andthe fabrication thereof are described in International PatentApplication No. PCT/US03/32763 having priority to U.S. patentapplication Ser. No. 10/272,065, filed Oct. 16, 2002, in the name ofGrant E. Wylie et al. and assigned to the same assignee as thisApplication.

The welding horns 74 and 76 may be offset along the processing path tominimize coupling of the vibratory ultrasonic energy between the horns.Alternatively, the anvil 78 may have an insert of yieldable materialswhich acts as a vibration isolator.

The assembled and slit product is driven at a driving or transportstation 104 downstream of the slitter 52. The transport station 104 hasa pair of belts 104 a and 104 b over motor driven pulleys which arebiased into engagement with the edges of the backing 92 and 94 and theyarn. The driving force propels the product downstream along theprocessing path. Take-up reels (not shown) may be provided on which thepile weatherseal product is wound for shipment to customers. The drivingforce for joining the threads 18 from the spool array 14 and 16 and fordrawing the monofilament along the frame loops 44 and 46 as well as fordriving the products to take up reels is provided by the driven belts inthe transport station 104. Except for the winding station 28, using theframe of ultrasonically weldable monofilament loops 44 and 46 and thewinding station having the ultrasonic welding means provided by thehorns 74 and 76 and the anvil 82, the apparatus illustrated in FIGS. 1,2 and 3 is similar to the apparatus described in the above referencedInternational Application No. PCT/US04/43314 and reference may be had tothat Application for further information with respect to the componentsof the apparatus shown in FIG. 1.

Referring to FIG. 4, there is shown an apparatus for making weatherseals10 and 12 by winding yarn from a spindle 22 at a winding station 28 andwelding backing strips 92 and 94 to the ends of the yarn at the bindingstation 72. The foregoing and other like parts of the apparatus shown inFIGS. 1-3, and in FIG. 4 are designated by like reference numerals. Thewinding frame in the apparatus shown in FIG. 4 is provided by a pair ofendless wire loops 110 and 112, preferable of metal such as stainlesssteel or titanium. The wire provides support for the loops as they arewound by yarn 24 drawn out from the rotating spindle 22. The loops 110and 112 have ends around free running support rollers 114 and 116 whichare mounted on shafts on brackets attached to a base provided by theframe of the machine. The opposite ends of the frame loops 110 and 112extend around the rollers 58 and 60 on the bracket 62 attached to thestationary support 30.

The wires 110 and 112 are guided through the winding station by notchesand slots in the anvil 78. The wire loops 110 and 112 extend through thecenter of the loops 26 via notches in the anvil similar to those shownat 84, 86, 88 and 90 in FIG. 3. The support loops 110 and 112 extendalong the processing path through the loops 26 until the loops are slitby a slitter 118 located along the processing path downstream of thetransport station 104.

Inasmuch as a special supply of filaments to provide the frame loops ofFIGS. 1-3 in the winding and binding stations 28 and 72 are not requiredin the apparatus shown in FIG. 4, the apparatus is simplified. The loop110 and 112 wire material does not bind to the yarn loops 26. The endsof the loops of yarn are ultrasonically welded together with the backingstrips 92 and 94 by the welding heads 74 and 76 which bear against thestrips 92 and 94, the ends of the loops 26 and the edges of the anvil78.

A further advantage of the use of wire loops in providing a product thatneed not be slit is obtained with the apparatus shown in FIGS. 5, 6A or6B and 7. There like parts to those shown in FIGS. 1 through 4 areidentified with like referenced numerals.

In the apparatus shown in FIGS. 5, 6A, 6B and 7, the anvil 120 isshorter along the processing path than the anvil 62: The anvil 120, likethe anvil 62, provides guidance for wire loops 122 and 124 in notches(like those in FIG. 3) along the center and edges of the anvil. Thesenotches at the downstream end of the anvil have arcuate and particularlysemi-circular shape when viewed from the top at 126 and 128 in FIGS. 6and 6A. Alternatively, rollers 130 and 132 (see FIG. 6B) may be imbeddedat the downstream end of the anvil where the wires in the loops 122 and124 turn, as the wires extend around the ends of the loops 122 and 124.

The product produced by the apparatus shown FIGS. 5, 6 and 7 isillustrated in FIG. 15. The loops 26 of yarn provide a continuous pilehaving sides 140 and 142. Adjacent loops 26 are welded to each other andto the backing strips 92 and 94 at the ends of the loops. Differentweatherseal and other pile articles may include the continuous loop pilearticles produced by the apparatus shown in FIGS. 5 to 7. These articlesmay have their backing strips in generally parallel relationship asshown in FIGS. 28 to 35, 37A and 37B, or the backing strips may bespaced along side each other in edge to edge relationships to provideresilient supports and seals which are shown in FIGS. 16 to 27. Thevarious types and applications or installations for the continuous looppile articles as shown in FIGS. 16 through 35, 37A and 37B are discussedin greater detail hereinafter.

Referring to FIGS. 8 and 9, there is shown mechanically operative meansfor maintaining a support 150 which like the support 30 (carrying thescotch yoke mechanism) maintains the winding station 28 fixed orstationary. The support 150, like the support 30, provides attachmentfor the rollers 58 and 60 and guide pins 64 and 66 which define theupstream end of the loops forming the winding frame extend. Theserollers 58 and 60 and pins 64 and 66 are attached to the support 150 bybrackets 152 and 154 which are laterally adjustable on the support 150by slot and screw arrangements 156 and 158, thereby enabling alignmentof the winding loops and frame and the defining the width of the pilearticles produced by the apparatus. The mechanism shown in FIGS. 8 and 9as well as the fluid powered mechanism shown in FIGS. 10 to 12 and themagnetic chuck mechanism shown in FIGS. 13 and 14 may be used asreplacements for the scotch yoke mechanism discussed in connection withFIGS. 1 through 7, and especially where the product production rate andthe speed of winding of yarn at a faster rate than practical with ascotch yoke support mechanism is desired.

In the FIGS. 8 and 9 mechanism, the shaft 20 which rotates the spindle22 via collar 24 is journalled, as by a bearing 160, in the support 150.The shaft 20 is also journalled in bearings 162 and 164 in a stationarybase of guide block 166, which may be mounted on the base or frame ofthe apparatus. Shafts 168 and 170 are journalled in sleeves 172 and 174through the guide block 166. Cams 176 and 178 are mounted at the ends ofthe shafts 168 and 170. These cams 176 and 178 are driven synchronously,with the rotation of the shaft 20 and the spindle 22 thereon, by drivebelts 180 and 182 attached to pulleys 190 keyed to the shafts 20, 168and 170.

The spindle 22 rotates through a gap 184 between the outer peripheralsurface of the support 150 and fingers 186 projecting from the guideblock 166. There are aligned holes 188 in the support block 150 andfingers 186.

Pins 192 and 194, guided by the holes 188 in the brackets 186, arebiased against the cams 176 and 178 by springs 196 which bear againstthe fingers 186.

In operation, the pins 192 and 194 are reciprocated by the cams 176 and178 into and out of the holes 188 in the support block 150. Thereciprocation of the pins 192 and 194 are synchronized with the rotationof the spindle 22, by virtue of their driven relationship from thespindle drive shaft 20. Thus, the pins 192 and 194 clear the gaps 184when the spindle enters and passes through these gaps. At other timesduring the cycle of rotation, except where the spindle 22 is passingthrough the gaps 184, one or both pins are in the holes 188 in thesupport block 150. The support block in maintained stationary and anytorque, which may be transmitted through the bearings 160 by which theshaft 20 is journalled in the support block 150, is prevented fromrotating the support block 150. Therefore, the support block 150, thewinding frame provided either by loops 44 and 46, 110 and 112, or 122and 124, and the winding station 28 are maintained stationary duringyarn winding operations.

A fluid pressure operated mechanism, which may be pneumatically operated(or alternatively may be hydraulically operated) for maintaining thewinding station stationary, is illustrated in FIGS. 10, 11 and 12. Partswhich provide functions like those or parts illustrated in FIGS. 8 and 9are designated with like referenced numerals.

Actuation of pins 200 and 202, from a base 166 which is stationary andhas fingers 186 outboard of the path of the spindle 24 and the windingstation support 150, is provided by pistons 204 and 206 in pneumaticcylinders 208 and 210. These cylinders are attached to the fingers 186,and drive the pins 200 and 202 which are attached to the pistons throughgaps 184 reciprocally with respect to the support block 150 andparticularly into the holes 188 therein. Pressurized air is switchedinto chambers on opposite side of the pistons 204 and 206 by a pneumaticswitching circuit which is shown in FIG. 12. This circuit is containedprincipally in a housing 212. The housing contains a timing cam 214driven by a belt drive 216 connected between pulleys on the shaft 20 anda shaft leading into the housing 212 which rotates the timing cam 214.

As shown in FIG. 12, a cam 214 operates control switching valves 220 and222 which actuate four way valves 224 and 226. These valves switch thecompressed air via lines 228 to the cylinder 208, and through lines 230to the cylinder 210. The force applied to these pistons may be adjustedby varying the size of orifices (not shown) in the lines 228 and 230.The pneumatic circuit and actuators shown in FIGS. 10, 11 and 12 providesupport via the pins 200 and 202 for the winding station by reciprocallymoving the pins through the gaps 184 in synchronism and timedrelationship with the rotation of the spindle 22. The fluid pressureoperated embodiment provides operation with even less vibration than themechanically actuated mechanism shown in FIGS. 8 and 9 and may bepreferred if still higher product production and winding rates aredesired.

Referring to FIGS. 13 and 14, there is shown a cylindrical support block150 which carries the brackets 152 and 154 and the rollers 58 and 60 andpins 64 and 66 which mount the extreme end of the winding frame of thewinding station. This support block and the winding station aremaintained stationary by being magnetically coupled to a stationarystator 240. The stator 240 is held stationary by the fingers 186projecting from the stationary support block 166, which is fixed to thebase or frame of the machine. An armature ring 242 is attached to thesupport 150. Permanent magnets 244 are spaced from each other around thestator ring 240. Permanent magnets 246 are spaced from each other aroundthe armature 242. The spacing of the magnets 246 corresponds to thespacing of the magnets 244. The spacing is no smaller than the radialdistance across the gap 184 between the armature 242 and stator 240through which the spindle 22 rotates. The magnets 244 and 246 arepolarized in the same direction so that the north and south poles lineup the field generated by these magnets 244 and 246. The field,therefore, is cumulative and sufficiently strong to prevent the supportblock 150 from rotating as for example from torque which is transferredthrough the shaft bearings 160 in the support block 150. Alternatively,only one of the armature or stator may have the magnets disposedtherein. In either case there is a radial magnetic field whicheffectively magnetically chucks and holds the support cylinder 150stationary referenced against the stationary support block 166.Reciprocating pins and their associated mechanical or hydraulic drivemechanisms are thus no longer needed.

The spindle 22 is preferably made with non-conductive material, such asplastic, so that electric currents are not induced therein which mightestablish a reverse magnetic field and impede the rotation of thespindle. The advantage of the electromagnetic mechanism for supportingthe winding station in stationary position is that the mechanism isentirely free of vibration and can afford still higher winding rates andproduct production than with the scotch yoke mechanism or the mechanismsshown in FIGS. 8 through 12.

Reference is now made to FIGS. 16 through 27 and 37 which show the pilearticles used as weatherseals and other devices for example used aselectrostatic discharge devices (FIGS. 25 and 26) or as a hinge (FIG.27). In the pile article of FIGS. 16 through 27, the continuous looppile 26 is formed into a bow or arch which can provide a supportsurface. If desired, a layer of fin material, such as polypropylenesheet material may be arranged inside or outside of the pile to act as afurther air and water infiltration seal. The manner in which such finsmay be provided may be similar to what is illustrated in the Johnson etal. patent referenced above, and in FIG. 36.

Referring to FIG. 36, the rollers 58A and 60A of the winding station 28are similar to the rollers 58 and 60 shown in FIG. 1. These rollers 58Aand 60A are lengthened so that they carry not only the winding framefilaments 44 and 46, but also bands 125 and 127 of fin material whichoverlay the winding frame loops 44 and 46. The bands 125 and 127 arefolded so as to have underlying parts 129 and 131 and overlying parts133 and 135. The underlying parts 129 and 131 are located with theiredges adjacent the ends of the loops 26 of yarn as the loops are woundaround the frame by the rotating spindle 22. The overlying parts 133 and135 of the bands are spaced inwardly of the side edges'of the lowerbands 129 and 131. The overlying parts 133 and 135 move in the directionof the arrow 141; while the underlying parts 129 and 132 move in thedirection of the arrows 143 and 145. The overlying parts 133 and 135 maybe pulled from reels of the fin material bands much like the filaments35 and 38 of filamentary material which provide the winding frame loops44 and 46.

When the loops reach the binding station 72, the lower most 129 and 131of the band are welded to the loops of yarn 26 and the outer sides 54and 56 of the winding frame filaments. The connection of the bands 125and 127 provided by the welding thereof enables the lower band to bepulled by the transport station. The upper most part 133 and 135 of thebands 125 and 127 are free to move through the binding station andthrough the loops 26 of yarn so that additional length of band 125 and127 may be pulled from the supply wheel thereof.

In FIG. 16, the backing strips 92 and 94 are attached by double-sidedtape strips 260 to a door or window to provide a resilient bowweatherseal 262. The weatherseal may be attached to a door edge whichbears against the edge of a door or a fixed panel as shown in FIG. 16Aand provides a sliding weatherseal. As shown in FIG. 16B, a pair of suchbow or arch weatherseals 262 a and 262 b may be applied to a pair ofdoors such as French doors and form a seal therebetween.

FIGS. 17, 17A and 17B are similar to FIGS. 16, 16 a and 16 brespectively, except that the adjacent edges of the backing strips 92and 94 are joined preferably by an ultrasonically welded joint 271. Itwill be apparent from FIGS. 16 and 17 that the height of the bow or archof weatherseal 262, 262 a or 262 b may be adjusted by the spacing of thebacking strips 92 and 94 from each other.

FIGS. 18A, 18B and 18C are similar to FIGS. 16, 16 a and 16 brespectively, except that the backing strips 92 and 94 are retained inT-slots 266 and 268. Such T-slots are similar to those used to retaincut pile weatherstrips.

FIG. 19 illustrates an arrangement of the bow or arch provided by thecontinuous loops or double-sided loops of pile 26 which provides asliding seal or a door sweep against a threshold 273 by being attachedat the bottom of a door.

FIG. 20 shows the bow or arch weatherseals 262 a and 262 b providingsliding seals which space and support doors which either swing towardeach other or slide with respect to each other.

FIG. 21 illustrates the bow or arch of the full loop weatherseal 262attached to the frame (style) 277 of a plate glass door 279 and providesa seal against the frame of the door. The bow or arch weatherseal 262provides support and a seal between a sash or a door which movesvertically with respect to a sill or laterally with respect to the framein which the door is mounted when the door slides against the frame (seeFIGS. 22 and 23). If the door swings over a threshold, the arch of theweatherseal on the bottom of the door sweeps the threshold, therebyproviding an improved door sweep.

FIG. 24 illustrates the full loop bow or arch weatherseal 262 arrangedas a compression seal when a door or sash 281 swings and bears againstthe bow or arch of the weatherseal. The advantages of such a sealingarrangement is low closing force, durability, reduction of air or waterinfiltration, and to present a wide sealing area.

Referring to FIGS. 37A and 37B there is shown a full loop weatherstrip262 configured to bridge an angle, for example formed by the corner of adoorframe 269, as shown in FIG. 37B. The backings are disposed to definethe angle which is to be bridged by the bow or arch weatherseal 262. Inthe case of a corner of a framework 269, the backings 92 and 94 areperpendicular to each other and may be disposed in T-slots 266 and 268.See FIG. 16 for the attachment of the backings 92 and 94 viadouble-sided tape 260.

As shown in FIG. 37B when a sash 271 of the window is brought down intothe corner of the framework 269, the bow or arch of the full loop pilearticle 262 provides a resilient base and a weatherseal at the corner ofthe sash 271.

FIGS. 25 and 26 illustrate full loop bow or pile articles archweatherseals 262, arranged in T-slots, providing electrical staticdischarged devices. The yarn in these devices 262 and 262 a and 262 bmay be of conductive material, such as by being impregnated with coppersulfate. Charges on paper or other medium, which is engaged by the bowor arch of these devices 262, 262 a and 262 b, is discharged through thedevices into the frame in which the device are installed. The devicescan be used to provide electrostatic seals which may be used to sealagainst electromagnetic interference into or out of a housing. Theadvantages of such seals are large sealing area to provide a completeelectromagnetic seal, ease of installation, low cost, durability and theability to reduce noise or vibration or interference with the movementof the medium (the paper) past the discharge device.

FIG. 27 shows a hinge mechanism using bow or arch 262 with its backingstrips in T-slots in a frame and in a door, a panel or a screen, whichmay be pivoted in the direction of the arrow 266. Bow or arch 262 mayprovide hinges at spaced positions or along the pivotal joint betweenthe frame and the door panel or screen.

FIG. 28 shows a device 276 similar to the weatherseal shown in FIG. 15wherein the backing strips 92 and 94 are spaced from each other onopposite sides of a slot 266 across which the continuous loops 26extend. The continuous loop device 276 provides a guide strip and sealfor a panel which extends into the slot 266 in the frame. The device 276advantageously reduces vibration, positions the panel, and provides acoefficient of sliding friction which enhances sliding movement of thepanel along the device 276. A fm on the inside or outside of the loopsmay be provided to enhance air and water tightness of the loops.

FIG. 29 illustrates the device 276 installed between spaced panels toprovide a continuous seal for sealing the space between the panels.

FIG. 30 shows the same device as in FIG. 29 but having a slit 278extending laterally through the loops. The slit provides a passagewayfor objects and enables the seal to be maintained. Thus, the seal actsas a light dust and dirt seal to prevent objects from entering an areathat is sensitive to light dust or dirt.

FIGS. 31 and 32 illustrate how a ring may be formed from a continuouslength of pile loop to provide a ring shaped spring mechanism 280. Theaxis 283 of the ring is generally through the center thereof. The pileor loop may be made in two parts each semicircular and welded at thebacking strip ends to provide joints 282 on opposite sides of thestructure.

FIG. 32 illustrates how the structure of mechanism 280 compresses andexpands laterally in response a movable load applied thereto in adirection against a fixed surface.

FIGS. 33 and 34 illustrates the continuous pile loop of FIG. 15providing a belt 282. The backing may be made of flexible material so asto engage pulleys 284, one of which may be driven. The belt may be usedas a drive belt to transfer rotary motion from one pulley to the other,or as a conveyor belt for items placed on the surface presented by theloops between the backing strips 92 and 94. The conveyor provides aresilient surface for supporting objects to be conveyed.

FIGS. 35A and 35B show continuous loop pile articles of FIG. 15 whichare sufficiently long to provide a filler 290 for an opening in acurtain, an upholstered item or a carpet. It may be preferable to useloops which are connected at their ends by ultrasonic welding withoutbacking strips or to textile backing strips, as discussed above. Suchloops may contain monofilaments internally thereof as discussed inconnection with FIGS. 1-3. In providing the article 290, the endportions may be attached by fabric basting 296. Stitching the bastingconnects panels containing the yarn loops 26. These panels beingsufficiently flexible to provide, when sewn together, a filler orcovering of desired width.

From the foregoing description it will be apparent that there has beenprovided improved methods and apparatus for making pile articles andparticularly weatherseals, brushes and the like. Numerous pile articlesand their applications have been shown and described. Of course,variations and modifications in the herein described apparatus andmethods and in the pile articles and their installations andapplications, within the scope of the invention, will undoubtedly becomeapparent to those skilled in the art. Accordingly the foregoingdescription should be taken as illustrative and not in a limiting sense.

1-40. (canceled)
 41. A pile article comprising a helically winding offilamentary material having loops with opposite sides and opposite ends,said loops being attached at the ends thereof to provide alongitudinally extending pile with both of said sides of said loop beingin proximity to provide a resilient support member.
 42. The pile articleaccording to claim 41 wherein said sides define an arch or bow whichprovides a support surface.
 43. The pile article according to claim 44wherein said loops present a sealing surface on an outside surface of atleast one of said sides.
 44. The pile article according to claim 41wherein backing strips are attached to and along at the ends of saidloops, said strips either being in generally parallel relationship, orin angularly related relationship with said pile forming a bridgetherebetween or an arch or bow between said strips and said adjacentedges either being spaced from or adjoining each other.
 45. The pilearticle according to claim 44 wherein said backing strips are assembledon a closing surface of a door or panel, said bow or arch projectingfrom said closing surface and presenting a resilient support or seal ata closing surface of another surface presented by a member providingpanel or frame.
 46. The pile article according to claim 45 wherein saidanother surface is opposite to said closing surface, another pilearticle having backing strips attached to said another surface andpresenting an arch or bow of pile loops engageable with said arch or bowprojecting from said closing surface.
 47. The pile article according toclaim 45 wherein said another surface is a threshold member.
 48. Thepile article according to claim 45 wherein said bow or arch on saidclosing surface is engageable with a pivotable door sash presenting aclosing surface.
 49. The pile article according to claim 44 wherein saidbacking strips are supported in a door or panel attached to a frame bythe bow or arch of said pile loops so as to define a hinge on which saiddoor or panel and frame are pivotably interconnected.
 50. The pilearticle according to claim 44 wherein a pile article having said bow orarch or a pair of said pile articles having said bows or arches haveloops of conductive filamentary material, and said bows and archespressing a surface or opposed surfaces past which a medium of paper orthe like are movable for discharge of electrostatic charge on saidmedium.
 51. The pile article according to claim 44 wherein said backingstrips are parallel to each other and disposed in support members whichare spaced from each other to define a gap across which said pile bridgeextends and at least one of said sides of said loop presents a supportor sealing surface.
 52. The pile article according to claim 51 whereinsaid loops have a slot which extends laterally through said loops andproviding a passageway for an object.
 53. The pile article according toclaim 44 wherein said loops provide a spring between members engagingsaid backing strips said backing strips each being engaged by adifferent one of said members so as to compress said spring provided bysaid loops.
 54. The pile article according to claim 53 wherein saidbacking strips and pile are arranged in a ring so that said pile definesa tubular spring.
 55. The pile article according to claim 44 whereinsaid backing strips are strips of flexible material arranged with saidpile therebetween in a belt, said belt being disposable around pulleysso that said belt rotates with said pulleys. 56-58. (canceled)
 59. Thepile article according to claim 41 wherein backing strips are attachedto and along the ends of said loops, said backing strips being disposedeither parallel to each other or in angular relationship, said bow orarch bridging said strips, and when said strips are in angularrelationship, bridging the angle between said strips.
 60. The pilearticle according to claim 59 wherein said backing strips are disposedon opposite sides of a corner defined by a frame and said bow or archpresents a resilient support or a sealing support across said corner fora member movable with respect to said frame into and out of said corner.